Sprouted popcorn and method for making sprouted popcorn

ABSTRACT

Systems and methods for producing sprouted popcorn kernels are provided, which can be popped into sprouted popped popcorn having unique organoleptic qualities. In an embodiment, a system incorporates a germination unit having one or more sensors to track the germination progress of unsprouted popcorn kernels and to automatically transition sprouted popcorn kernels to a drying process to provide dried sprouted popcorn kernels suitable for popping as a ready to eat product or for packaging for consumer popping preparation. The system promotes the preparation of commercial scale sprouted popcorn kernels through tracking of moisture content of the popcorn kernels through one or more processes of sprouted popcorn kernel production.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims the benefit under 35 U.S.C. § 119(e) ofU.S. Provisional Application Ser. No. 62/783,404, entitled SPROUTEDPOPCORN AND METHOD FOR MAKING SPROUTED POPCORN, filed Dec. 21, 2018, andU.S. Provisional Application Ser. No. 62/866,880, entitled SPROUTEDPOPCORN AND METHOD FOR MAKING SPROUTED POPCORN, filed Jun. 26, 2019.U.S. Provisional Application Ser. Nos. 62/783,404 and 62/866,880 arehereby incorporated by reference in their entireties.

BACKGROUND

Sprouting a grain changes characteristics of the grain such as itsflavor profile, texture, or nutrition. Sprouting a grain breaks down theouter hull, often making the grain more easily digestible, which canalso increase the bioavailability and amount of some vitamins.

Popcorn is a popular snack food that is made by heating a specializedpopcorn kernel so that the water inside the kernel turns to steam,causing pressure that ruptures the corn hull, and results in an expandedfluffy popped corn.

SUMMARY

This summary is provided solely as an introduction to subject matterthat is fully described in the detailed description and drawings. Thesummary should not be considered to describe essential features nor beused to determine the scope of the claims. Moreover, it is to beunderstood that both the summary and the detailed description areexamples and explanatory only and are not necessarily restrictive of thesubject matter claimed.

Aspects of the disclosure pertain to producing sprouted popcorn kernelsthat provide an ability for popping into sprouted popped popcorn havingunique organoleptic qualities. In an embodiment, a system incorporates agermination unit having one or more sensors to track the germinationprogress of unsprouted popcorn kernels and to automatically transitionsprouted popcorn kernels to a drying process to provide dried sproutedpopcorn kernels suitable for popping as a ready to eat product or forpackaging for consumer popping preparation. The system promotes thepreparation of commercial scale sprouted popcorn kernels throughtracking of moisture content of the popcorn kernels through one or moreprocesses of sprouted popcorn kernel production.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic diagram of a process for making sprouted popcorn.

FIG. 2 is a schematic diagram of a high throughput system for makingsprouted popcorn.

FIG. 3 is a schematic diagram of a control system for automatic controlof the high throughput system of FIG. 2 .

FIG. 4A is a photograph of an unsprouted popcorn kernel in whole form(top) and in cross section (bottom).

FIG. 4B is a photograph of a sprouted popcorn kernel in whole form (top)and cross section (bottom) prepared in accordance with exampleimplementations of the present disclosure.

FIG. 5A is a photograph of unsprouted popped popcorn.

FIG. 5B is a photograph of sprouted popped popcorn prepared inaccordance with example implementations of the present disclosure.

FIG. 6 is a photograph of side by side unsprouted popcorn (left) andpopped sprouted popcorn (right) prepared in accordance with exampleimplementations of the present disclosure.

FIG. 7 is a stereo microscopic view of unsprouted popped popcorn (left)and sprouted popped popcorn (right) prepared in accordance with exampleimplementations of the present disclosure.

DETAILED DESCRIPTION Overview

Whole grains provide many nutritive and digestive benefits to consumersby including the same basic components of the kernel harvested fromgrains. A whole grain includes the bran, the endosperm, and the germ,all or part of which can be encased or surrounded by a husk orprotective outer shell. Refined grains lack one or more of thesecomponents, for example, by separating the endosperms from the bran andgerm at the cost of separating out many nutritive and digestivebenefits. The bran is the outer skin of the kernel and providesimportant antioxidants, vitamins, and fiber. The endosperm typicallyforms the largest portion of the grain and contains a food supply forthe germ. The endosperm provides carbohydrates, proteins, and somevitamins and minerals. The germ is the embryo of the grain and has thepotential to sprout into a new plant given suitable growing or sproutingconditions. The germ includes a variety of vitamins, minerals, protein,and fats by containing concentrated oils and nutrients to facilitate thesprouting process.

Sprouting is the natural germination process by which seeds put outshoots. Sprouted whole grains can have altered characteristics of thegrain such as its flavor profile, texture, and nutrition as compared tounsprouted grain. For instance, sprouting a grain can break down,soften, or otherwise weaken the outer hull, which can make the grainmore easily digestible. Sprouting a grain may also increase the amountof some vitamins and/or their bioavailability during digestion.

However, sprouting a grain poses certain challenges in preparation offood products for consumption. If a grain is permitted to sprout toolong, the sprout begins to use up the nutrients stored in the grain topush the shoot farther from the grain, which can result in a decline ofthe nutrient content of the sprouted grain. Additionally, the conditionsfor sprouting a grain can be similar to conditions that facilitatebacterial pathogen growth. The general sprouting process involvessoaking the grain in water or another liquid to increase the moisturecontent and bring the grains out of dormancy. The soaked grains are thenrinsed, drained, and kept moist until the shoots (sprouts) begin toemerge. As such, the sprouting process introduces additionalantimicrobial challenges for food preparation of the sprouted grain ascompared with unsprouted grain food products.

Sprouting a grain poses additional challenges for popcorn. Popcorn ismade by heating the corn kernel so that the water inside the kernelturns to steam, causing pressure that ruptures the corn hull, andproduces the expanded fluffy popped corn. One issue for making sproutedpopcorn is that if popcorn is sprouted to the extent that the sproutextends outside the kernel (e.g., acrospires forming), the sprout mayburn during the popping process, which creates undesirable taste, odor,and appearance. Another issue is the moisture of the pre-popped cornkernel. Moisture levels to influence sprouting are too high to promotepopping. If the moisture remains too high, then the popcorn will notpop. Accordingly, the process for making sprouted popcorn may include adrying step. However, if the drying step is conducted so that themoisture of the final pre-popped popcorn is too low, then the desiredtextural qualities will not be achieved. These challenges are magnifiedfor commercial-scale throughput of sprouted grain food products,particularly with ensuring proper process steps for microbial control,sprouting conditions, drying conditions, and the like, for batch sizeson the order of hundreds of pounds of popcorn kernels.

Sprouted popcorn kernels and food products thereof and systems andmethods for production of sprouted popcorn kernels and food productsthereof are provided herein. In an embodiment, a system incorporates agermination unit having one or more sensors to track the germinationprogress of unsprouted popcorn kernels and to automatically transitionsprouted popcorn kernels to a drying process to provide dried sproutedpopcorn kernels suitable for popping as a ready to eat product or forpackaging for consumer popping preparation. The system promotes thepreparation of commercial scale sprouted popcorn kernels throughtracking of moisture content of the popcorn kernels through one or moreprocesses of sprouted popcorn kernel production.

Terminology & Aspects of the Disclosure

As used herein the terms “germination” and “sprouting” mean the processby which a seed ends dormancy and begins to grow into a plant.

The term “popped popcorn” as used herein generally refers to poppedpopcorn kernels having undergone a heating procedure to burst the hullof the kernel as a result of internal steam pressure.

The term “kernel” means unpopped or pre-popped popcorn, such as unpoppedor pre-popped popcorn kernels removed and isolated from a corn cob.

The term “room temperature” means a temperature from about 20° C. to 30°C., from about 23° C. to 27° C., generally about 25° C.

The term “about” used with reference to numerical values refers tonumbers including the referenced number and numbers having functionalequivalence to the referenced number.

Aspects of the disclosure include sprouted popcorn kernels, sproutedpopped popcorn, a ready to eat (RTE) sprouted popped popcorn product, amicrowavable sprouted popcorn kernel product, and processes to makesprouted popcorn kernels and sprouted popped popcorn. In one aspect, thedisclosure includes sprouted popcorn kernels and methods to make thesame. In one aspect, the sprouted popcorn kernels are provided in amicrowavable package. In one aspect, the disclosure includes sproutedpopped popcorn and methods to make such. In one aspect, the sproutedpopped popcorn is a packaged ready to eat (RTE) product. In one aspect,the sprouted popcorn kernels and popped popcorn are sourced from ahybrid popcorn seed variety, although generally any type of popcorn canbe used. In one aspect, the sprouted popcorn kernels are made from aprocess including the steps of soaking, germination, and drying. In oneaspect, the sprouted popped popcorn is made from a process including thesteps of soaking, germination, drying, and popping.

Processes and Systems for Making Sprouted Popcorn

Referring generally to FIGS. 1-3 , example processes and systems formaking sprouted popcorn kernels and sprouted popped popcorn are shown inaccordance with example implementations of the present disclosure. Anoverview of an example process 100 for making sprouted popped popcorn isprovided in FIG. 1 , an example high throughput system 200 for makingsprouted popcorn kernels and sprouted popped popcorn is provided in FIG.2 , and an example control system 300 for automating production aspectsof the high throughput system 200 is provided in FIG. 3 . The processesand systems of FIGS. 1-3 generally involve steps to receive andcondition popcorn kernels to facilitate controlled germination of thekernel to provide a sprouted popcorn kernel suitable for popping intosprouted popped popcorn having specific organoleptic properties (e.g.,described further herein with reference to FIGS. 5-7 ). The popcornkernels can include a variety of popcorn kernels and hybrid popcornkernels having a hull thickness to retain the steam pressure for aperiod of time suitable to gelatinize the starch before rupturing andproducing the popped kernel.

The process 100 of FIG. 1 generally includes steps of decontaminating(optional) 102, soaking 104, germinating 106, drying 108, and popping110. Kernels suitable for use in process 100 can be of a popcorn orhybrid variety having the hull characteristics described above. Themoisture content of the kernels prior to further processing can be in arange from about 10% to about 16% by weight. For example, the weightpercentage of moisture in the kernels can be from about 10%, 10.5%, 11%,11.5%, 12%, 12.5%, 13%, 13.5%, 14%, 14.5%, 15%, 15.5%, and 16% to about10%, 10.5%, 11%, 11.5%, 12%, 12.5%, 13%, 13.5%, 14%, 14.5%, 15%, 15.5%,and 16%. In an example implementation, the weight percentage of moisturein the kernels is from about 13% to about 14% by weight. For instance,the weight percentage of moisture in the kernels can be about 13.5% byweight. Following receipt of the popcorn kernels, the kernels can bedecontaminated or otherwise cleaned in step 102 through interactionbetween the kernels and antimicrobial agents, food-grade cleaning agentsand surfactants, or combinations thereof. For example, step 102 caninclude treating the unpopped kernels with a decontaminating agent suchas sodium hypochlorite (NaOCl) or NEO-PURE™ (an organic liquiddecontamination solution derived from plants). A number ofdecontamination methods and agents can be employed, so long as they meetefficacy and safety standards and do not interfere with furtherprocessing of the kernels or popping of the kernels.

The soaking step 104 prepares the unpopped kernel for germinating byproviding conditions for dormant seeds to begin the germination process.During the soaking step 104, the kernels are exposed to water or otherfluid to soften the hull and increase the fluid content of the kernel inpreparation for germination, which typically involves fluid contentsmuch higher than those of the initial kernels. The weight percentage offluid in the kernels following the soaking step 104 can be in a rangefrom about 25% to about 35%. For example, the weight percentage ofmoisture in the kernels following the soaking step 104 can be from about25%, 25.5%, 26%, 26.5%, 27%, 27.5%, 28%, 28.5%, 29%, 29.5%, 30%, 30.5%,31%, 31.5%, 32%, 32.5%, 33%, 33.5%, 34%, 34.5%, and 35% to about 25%,25.5%, 26%, 26.5%, 27%, 27.5%, 28%, 28.5%, 29%, 29.5%, 30%, 30.5%, 31%,31.5%, 32%, 32.5%, 33%, 33.5%, 34%, 34.5%, and 35%. In an exampleimplementation, the weight percentage of moisture in the kernelsfollowing the soaking step 104 is from about 29% to about 33% by weight.For instance, the weight percentage of moisture in the kernels followingthe soaking step 104 can be about 31%. During the soaking step 104, thekernels generally absorb moisture from the soaking solution, however theconditions for the soaking step 104 permit the kernel hulls to generallyremain intact to provide kernels suitable for a later popping process(e.g., popping step 110). The soaking step 104 can involve one or moreconditions to which the kernels are exposed prior to the germinatingstep 106. For example, kernels can be introduced to a soaking chamberfor a duration to soften the hull and increase the fluid content of thekernel in preparation for germination. The soaking chamber can bemaintained at a particular temperature, or have a varied temperature orgradient temperature during one or more soaking periods. The soakingstep 104 can also include introduction of one or more additives to thesoaking fluid. For example, flavoring, nutrients, or other agents can beadded to the soaking fluid for absorption by the kernels. Such additivescan influence conditions for germination, provide flavoring or nutrientsto an end sprouted popped popcorn, or the like.

Following the soaking step 104, the process 100 proceeds to thegerminating step 106 where the soaked kernels are introduced to acontrolled environment at a temperature and relative humidity for a timesufficient for the kernels to germinate and produce sprouted kernels.The conditions and duration of the germinating step 106 within thecontrolled environment can depend on the degree of germinationpreferred. For example, the germinating step 106 occurs mostly in theabsence of light where the popcorn kernels are germinated until thekernel hull thins but the developing sprout does not crack the kernelhull. The hull of the germinated kernels may be translucent due to thethinned state, but remains intact to prevent formation of acrospires.For instance, if acrospires were present external to the hull, theacrospires could burn during subsequent popping processes of thesprouted kernels, resulting in undesirable taste, odor, and appearance.Additionally, the germinating step 106 can control germinationconditions to prevent the kernel from sprouting too long, where thesprout begins to use up the nutrients stored in the grain to push theshoot farther from the grain. The germinating step 106 can includemaintaining the controlled environment at room temperature conditions,with a relative humidity ranging from about 30%, 31%, 32%, 33%, 34%,35%, 36%, 37%, 38%, 39%, 40%, 41%, 42%, 43%, 44%, 45%, 46%, 47%, 48%,49%, and 50% to about 30%, 31%, 32%, 33%, 34%, 35%, 36%, 37%, 38%, 39%,40%, 41%, 42%, 43%, 44%, 45%, 46%, 47%, 48%, 49%, and 50%. In an aspect,the germinating step 106 includes maintaining the controlled environmentat room temperature conditions with a relative humidity from about 35%to about 45%. For example, the germinating step 106 can includemaintaining the controlled environment at room temperature conditionswith a relative humidity of about 40%.

Following the germinating step 106, the process 100 proceeds to thedrying step 108 where moisture is removed from the sprouted kernels tofacilitate storage or popped sprouted popcorn production. The dryingstep 108 can include introducing the sprouted kernels into a heatedenvironment, passing gas or heated gas over the sprouted kernels, orother drying process to remove moisture from the sprouted kernels. Thedrying step 108 can include removing moisture from the sprouted kernelsto provide a moisture content by weight in the sprouted kernels rangingfrom about 14%, 14.1%, 14.2%, 14.3%, 14.4%, 14.5%, 14.6%, 14.7%, 14.8%,14.9%, 15%, 15.1%, 15.2%, 15.3%, 15.4%, 15.5%, 15.6%, 15.7%, 15.8%,15.9%, and 16% to about 14%, 14.1%, 14.2%, 14.3%, 14.4%, 14.5%, 14.6%,14.7%, 14.8%, 14.9%, 15%, 15.1%, 15.2%, 15.3%, 15.4%, 15.5%, 15.6%,15.7%, 15.8%, 15.9%, and 16%. In an aspect, the drying step 108 includesremoving moisture from the sprouted kernels to provide a moisturecontent by weight in the sprouted kernels ranging from about 14.5% toabout 15.5%. For example, the drying step 108 can include removingmoisture from the sprouted kernels to provide a moisture content byweight in the sprouted kernels of about 15%.

Following drying, the dried sprouted kernels can be either packaged orpopped, depending on the desired food product (e.g., dried sproutedkernels or sprouted popped popcorn, respectively). If the dried sproutedkernels are the desired food product, the process 100 proceeds to apackaging step 112 in which the dried sprouted kernels are introduced tofood packaging, such as glass containers (e.g., jars, bottles, etc.),plastic containers (e.g., bags, bins, vials, etc.), microwavable popcornbags having expandable gussets (e.g., as described in U.S. Pat. No.9,868,581, incorporated herein by reference), or other packaging, suchas according to commercial aseptic packaging processes or the like.Alternatively or additionally, the dried sprouted kernels can be poppedin the popping step 110 before being packaged as a ready to eat (RTE)product. The popping step 110 heats the moisture within the driedsprouted kernels to induce steam pressure within the hull and gelatinizethe starch before rupturing and producing the sprouted popped popcorn.The popping step 110 can utilize one or more processes for heating thedried sprouted kernels. For example, the popping step 110 can includeone or more of heated oil, heated air, microwave radiation, or the liketo induce popping of the dried sprouted kernels. In an aspect, thepopping step 110 utilizes an air popping process without added oil toprovide sprouted popped popcorn having a dense and crunchy texture. Forinstance, added oil can reduce the crunch of the sprouted popped popcornby having the starch absorb a portion of the oil.

Referring now to FIG. 2 , a high throughput system 200 for makingsprouted popcorn is provided. The system 200 is shown including aholding bin 202, a decontamination unit 204, a soaking tank 206, agermination unit 208, a drying unit 210, a popping device 212, and apackaging system 214 to receive and store unsprouted popcorn kernels,prepare the unsprouted popcorn kernels for germination, germinate theunsprouted popcorn kernels to produce sprouted kernels, and to popand/or package the sprouted kernels. The system 200 includes a controlsystem (e.g., control system 300 shown in FIG. 3 ) to track process andkernel conditions and automatically transition the system 200 from oneoperating state to a next operating state based on sensed process and/orkernel conditions. The control system 300 includes a controller 302 thatcan include one or more controller units that coordinate operations ofthe system 200, where multiple controllers can be communicativelyconnected (e.g., via a network). The holding bin 202 receives and storespopcorn kernels from suppliers for holding at the site of the system200. The holding bin 202 can include, but is not limited to, a grainsilo, a storage tank, a storage bin, a collapsible bulk storage bag(e.g., a 2000 lb. to 3000 lb. capacity bag), or the like, orcombinations thereof. The moisture content of the kernels stored in theholding bin 202 can be in a range from about 10% to about 16% by weight.For example, the weight percentage of moisture in the kernels in theholding bin 202 can be from about 10%, 10.5%, 11%, 11.5%, 12%, 12.5%,13%, 13.5%, 14%, 14.5%, 15%, 15.5%, and 16% to about 10%, 10.5%, 11%,11.5%, 12%, 12.5%, 13%, 13.5%, 14%, 14.5%, 15%, 15.5%, and 16%. In anexample implementation, the weight percentage of moisture in the kernelsin the holding bin 202 is from about 13% to about 14% by weight. Forinstance, the weight percentage of moisture in the kernels in theholding bin 202 can be about 13.5% by weight.

Unsprouted kernels held in the holding bin 202 are transferred to thedecontamination unit 204 or to the soaking tank 206 for initial cleaningor to begin conditioning of the kernels for germinating. The unsproutedkernels can be transferred in batches from about 100 lbs., 120 lbs., 140lbs., 160 lbs., 180 lbs., 200 lbs., 220 lbs., 240 lbs., 260 lbs., 280lbs., 300 lbs., 320 lbs., 340 lbs., 360 lbs., 380 lbs., 400 lbs., 420lbs., 440 lbs., 460 lbs., 480 lbs., and 500 lbs. to about 100 lbs., 120lbs., 140 lbs., 160 lbs., 180 lbs., 200 lbs., 220 lbs., 240 lbs., 260lbs., 280 lbs., 300 lbs., 320 lbs., 340 lbs., 360 lbs., 380 lbs., 400lbs., 420 lbs., 440 lbs., 460 lbs., 480 lbs., and 500 lbs. In an exampleimplementation, the batch size transferred from the holding bin 202 isfrom about 250 lbs. to about 400 lbs. For instance, the batch sizetransferred from the holding bin 202 can be about 340 lbs. However, thesystem 200 is not limited to such batch sizes, where the system 200 canbe utilized for smaller batches (e.g., less than 100 lbs.) or largerbatches (e.g., in excess of 500 lbs.).

Unsprouted kernels fed to the decontamination unit 204 can be introducedto an aperture in the decontamination unit 204 (e.g., open end, hatchentry in a side surface, etc.) via belt conveyor, auger, hopper, or thelike, or combinations thereof. In an aspect, a decontamination fluid ispresent in the decontamination unit 204 during introduction of theunsprouted kernels. Alternatively or additionally, decontamination fluidis introduced to the decontamination unit 204 with the unsproutedkernels present therein. The kernels can be decontaminated or otherwisecleaned in the decontamination unit 204 through interaction between thekernels and antimicrobial agents, food-grade cleaning agents andsurfactants, or combinations thereof. For example, the decontaminationfluid can include one or more of sodium hypochlorite (NaOCl), NEO-PURE™,or another food grade decontamination agent which maintains thestructural integrity of the hull of the kernels to permit popping at thepopping device 212 or by an end consumer. The decontamination fluid caninclude sodium hypochlorite at a range from about 2000 ppm, 3000 ppm,4000 ppm, 5000 ppm, 6000 ppm, 7000 ppm, 8000 ppm, 9000 ppm, 10,000 ppm,11,000 ppm, 12,000 ppm, 13,000 ppm, 14,000 ppm, 15,000 ppm, 16,000 ppm,17,000 ppm, 18,000 ppm, 19,000, and 20,000 ppm to about 2000 ppm, 3000ppm, 4000 ppm, 5000 ppm, 6000 ppm, 7000 ppm, 8000 ppm, 9000 ppm, 10,000ppm, 11,000 ppm, 12,000 ppm, 13,000 ppm, 14,000 ppm, 15,000 ppm, 16,000ppm, 17,000 ppm, 18,000 ppm, 19,000, and 20,000 ppm. The concentrationof decontamination agent and time of exposure can depend upon eachother, such as for example, higher concentrations of decontaminationagent can be exposed to the kernels for less time than lowerconcentrations of decontamination agent. In an example implementation,the decontamination fluid includes 2000 ppm sodium hypochlorite with acontact time of 18 minutes with the kernels within the decontaminationunit 204. In an example implementation, the decontamination fluidincludes 5000 ppm NEO-PURE™ sprayed or otherwise applied to the kernelsfor a contact time of about 30 seconds to about 60 seconds prior todecomposition of the NEO-PURE™. The system 100 can include a restingperiod following decontamination prior to soaking. The resting periodcan be from about 30 minutes to about 120 minutes. For instance, theresting period can be about one hour.

Following decontamination, the kernels and the decontamination fluid areseparated and the kernels are transferred to the soaking tank 206 toprepare the unsprouted kernels for germinating. Separation of thekernels and the decontamination fluid can include draining thedecontamination fluid from an outlet in the decontamination unit 204,decomposition of the decontamination fluid (e.g., for use of NEO-PURE™),removal of the kernels from the decontamination unit 204, orcombinations thereof. In implementations, portions of thedecontamination process and the soaking process are conducted within thesame vessel (e.g., the decontamination unit 204 and the soaking tank 206share one or more common regions). Alternatively, the decontaminationunit 204 and the soaking tank 206 are distinct vessels or regions. Thesoaking tank 206 has a volume suitable to hold the kernels and a soakingfluid (e.g., water, water with added materials, etc.) through one ormore stages of soaking. The unsprouted kernels can be introduced to anaperture in the soaking tank 206 (e.g., open end, hatch entry in a sidesurface, etc.) via belt conveyor, auger, hopper, fluidized transfer of akernel slurry, or the like, or combinations thereof. In an aspect, asoaking fluid is present in the soaking tank 206 during introduction ofthe unsprouted kernels. Alternatively or additionally, soaking fluid isintroduced to the soaking tank 206 with the unsprouted kernels presenttherein. In an aspect, the soaking tank 206 includes a fluid levelsensor 216 to measure a level of soaking fluid present in the interiorof the soaking tank 206. The fluid level sensor 216 can include, but isnot limited to an ultrasonic sensor, an optical sensor, or other sensor,configured to measure a level or amount of fluid within the soaking tank206. A system controller (e.g., controller 302 in FIG. 3 ) for thesystem 200 can receive an output from the fluid level sensor 216 tocoordinate operation of a pump or other device to introduce fluid to thesoaking tank (e.g., when the output from the fluid level sensor 216indicates a fluid level under a threshold fluid level) or remove fluidfrom the soaking tank 206 (e.g., when the output from the fluid levelsensor 216 indicates a fluid level above a threshold fluid level). In animplementation, the threshold fluid level ranges from about one inch toabout six inches from a bottom surface of the soaking tank 206. Forexample, the threshold fluid level can be about two inches from a bottomsurface of the soaking tank 206. In an implementation, the thresholdfluid level ranges from about one inch to about six inches from a topsurface of kernels present in the soaking tank 206. For example, thethreshold fluid level can be about two inches from a top surface ofkernels present in the soaking tank 206.

While in the soaking tank 206, the kernels are contacted with thesoaking fluid to soften the hull and increase the fluid content of thekernel in preparation for germination. The soaking process within thesoaking tank 206 can involve one or more soaking stages, one or more ofwhich can have different lighting conditions. For example, differingsoaking stages can include different temperatures or times of soaking orlighting exposure. In an aspect, the soaking tank 206 is controlled(e.g., via controller 302) to provide a one stage soaking process wherethe kernels are contacted with the soaking fluid for a period of time ata substantially constant temperature. For example, the soaking tank 206can be controlled to maintain substantially room temperature conditionsfor a duration ranging from about 10 hours to about 14 hours. Forinstance, the soaking tank 206 can be controlled to maintainsubstantially room temperature conditions for a duration of about 12hours.

In an aspect, the soaking tank 206 can be controlled (e.g., viacontroller 302) to provide a multi-stage soaking process. For example,the multi-stage soaking process can include an activation stage and asteeping stage. The activation stage generally involves soaking thekernels in soaking fluid at a higher temperature than the steeping stageand for a shorter period of time than the steeping stage provide aninitial activation or “waking up” of the dormant seeds. In an aspect,the activation stage controls the soaking tank 206 to have a temperatureranging from about 30° C., 32° C., 34° C., 36° C., 38° C., 40° C., 42°C., 44° C., 46° C., 48° C., 50° C., 52° C., 54° C., 56° C., 58° C., and60° C. to about 30° C., 32° C., 34° C., 36° C., 38° C., 40° C., 42° C.,44° C., 46° C., 48° C., 50° C., 52° C., 54° C., 56° C., 58° C., and 60°C. In an example implementation, the activation stage involves atemperature ranging from about 39° C. to about 45° C. For example, theactivation stage can control the temperature of the soaking tank 206 toabout 42° C. The duration of the activation stage can range from about15 minutes, 30 minutes, 45 minutes, 60 minutes, 75 minutes, 90 minutes,105 minutes, and 120 minutes to about 15 minutes, 30 minutes, 45minutes, 60 minutes, 75 minutes, 90 minutes, 105 minutes, and 120minutes. For example, the activation stage can range from about 15minutes to about 60 minutes to activate the dormant kernels prior to thesteeping stage. The activation stage can be performed in the absence oflight. Following the activation stage, the temperature of the soakingtank 206 is reduced for the steeping stage. In an aspect, cooler wateris added to the soaking tank 206. For example, the controller 302 canautomatically control a pump or other device to permit the addition ofcooler water (e.g., room temperature water) to the soaking tank 206following the activation stage. In implementations, the controller 302utilizes a coordinated clock or timer to determine the end of theactivation stage. In an aspect, the steeping stage involves permittingthe soaking tank 206 to achieve about room temperature for a durationranging from about 4 hours, 4.5 hours, 5 hours, 5.5 hours, 6 hours, 6.5hours, 7 hours, 7.5 hours, and 8 hours to about 4 hours, 4.5 hours, 5hours, 5.5 hours, 6 hours, 6.5 hours, 7 hours, 7.5 hours, and 8 hours.In an example implementation, the soaking tank 206 maintains about roomtemperature soaking conditions following the activation stage for aduration of about 6 hours to about 7 hours. For example, the steepingstage has a duration of about 6.5 hours. The steeping stage can beperformed in the presence of light.

In an aspect, the system 200 includes a moisture sensor 218 tofacilitate operation of the soaking tank 206. The moisture sensor 218can include a non-contact sensor (e.g., a non-contact infrared sensor)or a contact sensor to measure a moisture of one or more kernels treatedby the soaking tank 206. For example, one or more kernels can be removedfrom the soaking fluid (e.g., via paddle wheel, conveyor, or otherautomated structure), coordinated by a controller of the system 200(e.g., controller 302), to bring the kernel in proximity to the moisturesensor 218. The controller 302 can receive an output from the moisturesensor 218 to coordinate operation of a pump, drain, conveyor, or otherdevice to separate the soaked kernels from the soaking fluid (e.g., viaremoval of one or more of the soaking fluid or the kernels from thesoaking tank 206) when the output indicates that the measured moisturemeets a threshold moisture content. In an aspect, the threshold moisturecontent can be a weight percentage of fluid in the kernels in a rangefrom about 25% to about 35%. For example, the threshold moisture contentcan be a weight percentage of moisture in the kernels following soakingin the soaking tank 206 from about 25%, 25.5%, 26%, 26.5%, 27%, 27.5%,28%, 28.5%, 29%, 29.5%, 30%, 30.5%, 31%, 31.5%, 32%, 32.5%, 33%, 33.5%,34%, 34.5%, and 35% to about 25%, 25.5%, 26%, 26.5%, 27%, 27.5%, 28%,28.5%, 29%, 29.5%, 30%, 30.5%, 31%, 31.5%, 32%, 32.5%, 33%, 33.5%, 34%,34.5%, and 35%. In an example implementation, the threshold moisturecontent is a weight percentage of moisture in the kernels from about 29%to about 33% by weight. For instance, the threshold moisture content canbe a weight percentage of moisture in the kernels of about 31%.Operation of the soaking tank 206 permits the kernels to absorb moisturefrom the soaking fluid while permitting the kernel hulls to generallyremain intact to provide kernels suitable for a later popping process(e.g., at the popping device 212 or by an end consumer). In an aspect,the soaking tank 206 includes an impeller or other agitation system tostir or otherwise agitate the kernels within the soaking tank 206 on acontinuous or intermittent basis. For example, the soaking tank 206 canagitate the kernels for a first duration (e.g., a first portion of thesteeping stage, such as a 30 minute duration) and can prevent agitationof the kernels for a second duration (e.g., a second portion of thesteeping stage, such as a 6 hour duration following the 30 minuteagitation period). In an aspect, all or a portion of the steeping stageis performed in the presence of light.

Following soaking, the kernels are separated from the soaking fluid andtransferred to the germination unit 208 for controlled sprouting of thesoaked kernels. Separation of the kernels and the soaking fluid caninclude draining the soaking fluid from an outlet in the soaking tank206, removal of the kernels from the soaking tank 206, or combinationsthereof, operated under control by the control system 300. Inimplementations, portions of the soaking process and the germinatingprocess are conducted within the same vessel (e.g., the soaking tank 206and the germination unit 208 share one or more common regions).Alternatively, the soaking tank 206 and the germination unit 208 aredistinct vessels or regions. A rinse procedure can be conductedfollowing soaking. For example, one or more of the soaking tank 206 orthe germination unit 208 can include a rinse fluid port to introduce arinse fluid to the soaked kernels prior to germinating the kernels. Inan aspect, the germination unit 208 supports the soaked kernels on oneor more porous trays to facilitate air circulation past the kernels.Alternatively or additionally, the germination unit 208 can include oneor more fans or air circulation devices to facilitate air circulationpast the kernels.

The germination unit 208 controls the conditions to which the soakedkernels are maintained in order to germinate and produce sproutedkernels. For instance, the soaked kernels are exposed to an environmenthaving controlled humidity, temperature, and lighting to germinate thekernels until the kernel hull thins, but the developing sprout does notcrack the kernel hull, preventing the formation of acrospires. Forinstance, if acrospires were present external to the hull, theacrospires could burn during subsequent popping processes of thesprouted kernels in the popping device 212 or by an end consumer,resulting in undesirable taste, odor, and appearance. Additionally, thegermination unit 208 controls germination conditions to prevent thekernel from sprouting too long, where the sprout begins to use up thenutrients stored in the grain to push the shoot farther from the grain.In particular, the germination unit 208 controls the relative humidityand light exposure of an internal volume in which the soaked kernels aremaintained during germination. In an aspect, the germination unit 208maintains a dark environment (e.g., substantially devoid of light)during the germinating process. The germination unit 208 can includehumidifier units and/or dehumidifier units to maintain a controlledenvironment for the soaked kernels with a relative humidity ranging fromabout 30%, 31%, 32%, 33%, 34%, 35%, 36%, 37%, 38%, 39%, 40%, 41%, 42%,43%, 44%, 45%, 46%, 47%, 48%, 49%, 50%, 51%, 52%, 53%, 54%, 55%, 56%,57%, 58%, 59%, 60%, 61%, 62%, 63%, 64%, 65%, 66%, 67%, 68%, 69%, and 70%to about 30%, 31%, 32%, 33%, 34%, 35%, 36%, 37%, 38%, 39%, 40%, 41%,42%, 43%, 44%, 45%, 46%, 47%, 48%, 49%, 50%, 51%, 52%, 53%, 54%, 55%,56%, 57%, 58%, 59%, 60%, 61%, 62%, 63%, 64%, 65%, 66%, 67%, 68%, 69%,and 70%. In an aspect, the germination unit 208 maintains the controlledenvironment with a relative humidity from about 35% to about 45%. Forexample, the germination unit 208 can maintain the controlledenvironment with a relative humidity of about 40%. In an aspect, thegermination unit 208 operates at room temperature conditions.

The germination unit 208 also controls the duration of the germinatingprocess. In an aspect, the germination unit 208 maintains the controlledenvironment of the soaked kernels for a specified duration to provide atleast 90% germination of kernels where the kernel hull thins, but thedeveloping sprout does not crack the kernel hull, preventing theformation of acrospires. In an aspect, the germination unit 208automatically maintains the controlled environment (e.g., facilitated bythe controller 302) to provide at least 95% germination of the soakedkernels. For example, the germination unit 208 can hold the soakedkernels within the germination unit for a duration ranging from about 8hours, 8.5 hours, 9 hours, 9.5 hours, 10 hours, 10.5 hours, 11 hours,11.5 hours, 12 hours, 12.5 hours, 13 hours, 13.5 hours, 14 hours, 14.5hours, 15 hours, 15.5 hours, and 16 hours to about 8 hours, 8.5 hours, 9hours, 9.5 hours, 10 hours, 10.5 hours, 11 hours, 11.5 hours, 12 hours,12.5 hours, 13 hours, 13.5 hours, 14 hours, 14.5 hours, 15 hours, 15.5hours, and 16 hours. The germination unit 208 can include a timercommunicatively coupled with the controller of the system 200 tocoordinate operation of the germination unit 208 with a system clock toautomatically stop the germinating process upon expiration of a pre-settime.

The germination unit 208 can include one or more germination sensors 220used to control the duration of the germinating process in addition toor as an alternative to a timer. For instance, the germination sensor220 can include one or more of an optical sensor or a moisture sensor,the output of which is used to control when the germination unit 208ceases providing the controlled environment for the germinating process.The optical sensor can include a camera, an optical coherence tomography(OCT) device, or other sensor configured to measure surface orsub-surface features of the kernels during the germinating process. Theoptical sensor can be activated on a continuous or intermittent basis tomeasure progress of the germinating process according to opticalmeasurements. In an aspect, the optical measurements are comparedagainst reference optical characteristics indicative of germinationprogress sufficient to provide sprouted kernels having a thinned and/ortranslucent hull that remains intact (e.g., without significantacrospire development). For example, the controller 302 can becommunicatively coupled with the optical sensor to compare output of theoptical sensor with the reference optical characteristics to determinewhether the measured kernel(s) have undergone a sufficient duration ofgermination. The reference optical characteristics can include, but arenot limited to, a number of acrospires present, a percentage ofacrospires present, a hull opacity, a range of hull opacity, and thelike. When the optical sensor output meets a threshold reference opticalcharacteristic (e.g., an optical measurement of the popcorn kernels atleast substantially matches (e.g., within two standard deviations) anoptical measurement of sprouted popcorn kernels prior to acrospireformation, one or more acrospires are detected, a hull opacity isreached indicating translucent hull characteristics, etc.), thecontroller 302 transmits control signals to the germination unit 208 tostop the germinating process and to initiate transfer of the sproutedkernels to the drying unit 210.

In an aspect, the moisture sensor of the germination sensor 220 providesan indicator to determine whether the measured kernel(s) has/haveundergone a sufficient duration of germination. For example, if theoptical sensor output meets the threshold reference opticalcharacteristic (e.g., as processed by the controller 302), the output ofthe moisture sensor can be checked to determine whether the moisture ofmeasured kernel(s) is/are within a threshold moisture content forkernels at the end of the germinating process (e.g., as processed by thecontroller 302). In an aspect, the germinating process is terminatedonly when each of the optical sensor output and the moisture sensoroutput are within the respective threshold values. Alternatively,moisture measurements from the moisture sensor are used to trigger theend of the germinating process at the germination unit 208. The moisturesensor can include a non-contact sensor (e.g., a non-contact infraredsensor) or a contact sensor to measure a moisture of one or more kernelstreated by the germination unit 208. For example, one or more kernelscan be removed from the tray of the germination unit 208 (e.g., viaconveyor or other automated structure), coordinated by a controller ofthe system 200, to bring the kernel in proximity to the moisture sensor.Alternatively or additionally, the moisture sensor is moved intoproximity of the kernels above the tray, below the tray (e.g., with anaperture or mesh on a bottom surface of the tray), or combinationsthereof. The controller 302 can receive an output from the moisturesensor of the germination sensor 220 to coordinate operation of aconveyor, air handler, or other device to transfer the sprouted kernelsto the drying unit 210 or being drying at the germination unit 208(e.g., when germinating and drying steps are consolidated at thegermination unit 208) when the output from the germination sensor 220indicates that the measured moisture meets a threshold moisture content.In an aspect, the threshold moisture content following germination canbe a weight percentage of fluid in the sprouted kernels in a range fromabout 20% to about 35%. For example, the threshold moisture content canbe a weight percentage of moisture in the sprouted kernels followinggerminating in the germination unit 208 from about 20%, 20.5%, 21%,21.5%, 22%, 22.5%, 23%, 23.5%, 24%, 24.5%, 25%, 25.5%, 26%, 26.5%, 27%,27.5%, 28%, 28.5%, 29%, 29.5%, 30%, 30.5%, 31%, 31.5%, 32%, 32.5%, 33%,33.5%, 34%, 34.5%, and 35% to about 20%, 20.5%, 21%, 21.5%, 22%, 22.5%,23%, 23.5%, 24%, 24.5%, 25%, 25.5%, 26%, 26.5%, 27%, 27.5%, 28%, 28.5%,29%, 29.5%, 30%, 30.5%, 31%, 31.5%, 32%, 32.5%, 33%, 33.5%, 34%, 34.5%,and 35%.

Following germination, the sprouted kernels are ready for drying toprovide a dried sprouted kernel having a final moisture content suitablefor popping (e.g., at the popping device 212) or to facilitate storagefor a later popping process (e.g., by an end consumer). Inimplementations, portions of the germinating process and the dryingprocess are conducted within the same vessel (e.g., the germination unit208 and the drying unit 210 share one or more common regions).Alternatively, the germination unit 208 and the drying unit 210 aredistinct units or regions. The drying unit 210 can include a heatedinterior in which the sprouted kernels are positioned and/or throughwhich the sprouted kernels are transferred (e.g., via conveyor). In anaspect, the drying unit 210 includes one or more fans or gas circulatorsto move gas or heated gas past the sprouted kernels to induce orotherwise facilitate removal of moisture from the sprouted kernels. Thedrying unit 210 maintains the sprouted kernels within a controlleddrying environment to remove moisture from the sprouted kernels toprovide a moisture content by weight in the sprouted kernels rangingfrom about 14% to about 16%. For example, the dried sprouted kernels canhave a moisture content by weight ranging from about 14%, 14.1%, 14.2%,14.3%, 14.4%, 14.5%, 14.6%, 14.7%, 14.8%, 14.9%, 15%, 15.1%, 15.2%,15.3%, 15.4%, 15.5%, 15.6%, 15.7%, 15.8%, 15.9%, and 16% to about 14%,14.1%, 14.2%, 14.3%, 14.4%, 14.5%, 14.6%, 14.7%, 14.8%, 14.9%, 15%,15.1%, 15.2%, 15.3%, 15.4%, 15.5%, 15.6%, 15.7%, 15.8%, 15.9%, and 16%.In an aspect, the drying unit 210 removes moisture from the sproutedkernels to provide a moisture content by weight in the sprouted kernelsranging from about 14.5% to about 15.5%. For example, the drying unit210 can remove moisture from the sprouted kernels to provide a moisturecontent by weight in the sprouted kernels of about 15%. In an exampleimplementation, the drying unit 210 operated at about 150° F. (65.6° C.)with about 30,000 cubic feet per minute (CFM) for about two hours. Thedrying unit 210 can include an agitator, stir device, or other structureto continuously or intermittently mix the sprouted kernels during thedrying process. In an aspect, the drying unit 210 maintains a darkenvironment (e.g., substantially devoid of light) during at least aportion of the drying process.

The drying unit 210 controls the duration of the drying process toprovide controlled conditions under which the dried sprouted kernels areproduced to provide the desired organoleptic features. For example, thedrying unit 210 can include a timer communicatively coupled with thecontroller 302 to coordinate operation of the drying unit 210 with asystem clock to automatically stop the drying process upon expiration ofa pre-set time. The drying unit 210 can include one or more moisturesensors 222 used to control the duration of the drying process inaddition to or as an alternative to a timer. The moisture sensor 222 caninclude a non-contact sensor (e.g., a non-contact infrared sensor) or acontact sensor to measure a moisture of one or more sprouted kernelstreated by the drying unit 210. For example, one or more sprouts kernelscan be removed from the tray of the drying unit 210 (e.g., via conveyoror other automated structure), coordinated by the controller 302, tobring the kernel in proximity to the moisture sensor 222. Alternativelyor additionally, the moisture sensor 222 is moved into proximity of thekernels above the tray, below the tray (e.g., with an aperture or meshon a bottom surface of the tray), or combinations thereof. Thecontroller 302 can receive an output from the moisture sensor 222 tocoordinate operation of a conveyor, air handler, or other device of thedrying unit 210 to stop the drying process when the output from themoisture sensor 222 indicates that the measured moisture meets athreshold moisture content. In an aspect, the threshold moisture contentfollowing drying can be a weight percentage of fluid in the driedsprouted kernels in a range from about 14% to about 16%. For example,the threshold moisture content can be a weight percentage of moisture inthe dried sprouted kernels following treatment in the drying unit 210from about 14%, 14.1%, 14.2%, 14.3%, 14.4%, 14.5%, 14.6%, 14.7%, 14.8%,14.9%, 15%, 15.1%, 15.2%, 15.3%, 15.4%, 15.5%, 15.6%, 15.7%, 15.8%,15.9%, and 16% to about 14%, 14.1%, 14.2%, 14.3%, 14.4%, 14.5%, 14.6%,14.7%, 14.8%, 14.9%, 15%, 15.1%, 15.2%, 15.3%, 15.4%, 15.5%, 15.6%,15.7%, 15.8%, 15.9%, and 16%. In an aspect, threshold moisture contentby weight in the dried sprouted kernels ranges from about 14.5% to about15.5%. For example, the threshold moisture content by weight in thedried sprouted kernels is about 15%.

Following drying at the drying unit 210, the dried sprouted kernels canbe transferred to one or more of the popping device 212 (e.g., toproduce a sprouted popped popcorn RTE product) or the packaging system214 (e.g., to package sprouted unpopped popcorn) via conveyor, auger, orother food handling system. The popping device 212 includes a heater toheat the dried sprouted kernels directly or indirectly, such as throughone or more of conductive heat, convection, or radiation. The poppingdevice 212 can utilize one or more of heated oil, heated air, microwaveradiation, or the like to induce popping of the dried sprouted kernels.In an aspect, the popping device 212 passes heated air or other gas pastthe dried sprouted kernels to induce steam pressure within the hull andgelatinize the starch before rupturing and producing the sprouted poppedpopcorn. The sprouted popped popcorn is then transferred from thepopping device 212 to the packaging system 214, such as through actionof a conveyor, auger, or other food handling system.

The packaging system 214 receives the dried sprouted kernels from thedrying system 210 and the sprouted popped popcorn from the poppingdevice 212 for introducing the respective food products into packaging,such as glass containers (e.g., jars, bottles, etc.), plastic containers(e.g., bags, bins, vials, etc.), microwavable popcorn bags havingexpandable gussets (e.g., as described in U.S. Pat. No. 9,868,581,incorporated herein by reference), or other packaging, such as accordingto commercial aseptic packaging processes or the like.

Example 1 Benchtop Germination

An implementation of a benchtop process for producing sprouted poppedpopcorn was performed in accordance with example implementations of thepresent disclosure. An Easy Sprout grain sprouter was utilized to aid inthe germination process. Moisture content was measured using a DickeyJohn GAC2100b moisture analyzer. A charge of 250 grams popcorn kernelshaving a moisture of 13.5 wt. % was soaked for 12 hours in 1000 gramswater at room temperature. The bed depth was 2 inches and no agitationwas used. The kernels were drained and shaken to remove water. Thekernels were returned to the steeping container and left at 18 hours atroom temperature and about 40% relative humidity. The bed height was 3inches (due to water absorption). The container was not agitated.Following germination, the kernels were dried by blotting and then on ametal sheet at 53° C. for 5 to 8 hours at single kernel depth withoutagitation. Final moisture content was 14 to 15 wt. %; the moisture waschecked every 30 minutes starting at 5 hours to ensure moisture was notbelow 14 wt. %. Dried kernels were stored at ambient temperature inmetallized bags. An air popper was used to pop the sprouted kernels.Sprouted popped popcorn was stored in metalized bags.

Example 2 Commercial Scale Germination

An implementation of a commercial scale process of making sproutedpopcorn kernels was performed in accordance with example implementationsof the present disclosure. The commercial scale example began with 340lb. popcorn at a beginning moisture of about 13% to 14% by weight. Adecontamination step was performed which involved exposing the popcornkernels to 2000 ppm sodium hypochlorite for 18 minutes. Afterdecontamination, the kernels were soaked in a two-stage processinvolving an activation stage followed by a steeping stage. The kernelswere submerged in water in a steeping tank at a temperature of about 42°C. for about 15 to 60 minutes. Additional water was added to lower thetemperature to about 25° C. and the kernels steeped for about 6.5 hourswith intermittent mixing for the first 30 minutes. The moisture contentof the kernels following soaking was about 31%. Germination wasconducted using sprouting trays heaped with kernels. The step wasconducted in the dark at a temperature of about 25° C. for about 14 to16 hours. The germinated kernels were dried to a moisture content ofabout 14.5 wt. % to about 15.5 wt. % moisture using the same trays usedin the germination step. A tray of about 340 pounds was heated at 60° C.for about 2 hours with air flow of about 30,000 CFM. The kernels weremixed every hour. Germinated and dried kernels were packaged as poppablekernels and also as ready to eat (RTE) air-popped popcorn.

Characteristics of the Sprouted Popcorn Kernels and Sprouted PoppedPopcorn

Sprouted popcorn kernels prepared in accordance with exampleimplementations of the present disclosure differ in appearance fromunsprouted kernels. Specifically, the hull of the sprouted popcornkernels generally appears thinner and somewhat translucent as comparedto a thicker and opaque hull of unsprouted kernels. Referring generallyto FIGS. 4A and 4B, specimens of unsprouted kernels and sprouted kernelsthat have been prepared in accordance with example implementations ofthe present disclosure are shown. FIG. 4A illustrates unsprouted kernelsin whole (top) and in cross-section (bottom) having a moisture contentof about 13.5 wt. % and FIG. 4B illustrates sprouted kernels in whole(top) and in cross-section (bottom) having a moisture content of about14.5 wt. %.

Sprouted popped popcorn prepared from sprouted popcorn kernels inaccordance with example implementations of the present disclosure isdifferent from unsprouted popped popcorn in several ways. The volume ofsprouted popped popcorn is less than the volume of the unsprouted poppedpopcorn by around 50% in some cases, and the mass is only slightly less.Accordingly, the density is significantly higher for the sprouted poppedpopcorn. Color and texture differences are also found, as shown furtherwith respect to Tables 1 and 2.

Referring generally to FIGS. 5A and 5B, bulk specimens of unsproutedpopped popcorn and sprouted popped popcorn prepared in accordance withexample implementations of the present disclosure are shown. FIG. 5Aillustrates a bulk specimen of unsprouted popped popcorn and FIG. 5Billustrates a bulk specimen of sprouted popped popcorn, where thesprouted popped popcorn has a noticeably higher bulk density as comparedto unsprouted popcorn. FIG. 6 illustrates a side by side comparison of aspecimen of unsprouted popped popcorn (left) and a specimen of sproutedpopped popcorn. Photographs of the specimens of FIG. 6 viewed through astereo microscope at 8 times magnification are shown in FIG. 7 , withthe unsprouted popped popcorn (left) having a cracked interior and thesprouted popped popcorn (right) have a webbed appearance withcharacteristics of a closed-cell foam (e.g., Styrofoam).

Table 1 illustrates qualitative comparisons between sprouted poppedpopcorn prepared from sprouted popcorn kernels in accordance withexample implementations of the present disclosure and unsprouted poppedpopcorn.

TABLE 1 Sprouted Unsprouted Volume Low High Density High Low ColorYellow-tint White Texture Crunchy Soft/chewy

Table 2 illustrates quantitative comparisons between sprouted poppedpopcorn prepared from sprouted popcorn kernels in accordance withexample implementations of the present disclosure and unsprouted poppedpopcorn.

TABLE 2 Sprouted Unsprouted Volume from 66 g 1350 3210 kernels ml (cm³)Density (g/cm³) 0.037 0.016 Color L*, a*, b* 83.78, 3.61, 22.50 86.15,3.24, 19.03 Texture - # peaks 7 23 Texture - peak force (g) 31899.524519.5

Texture was based on 1.5 g of popped kernels and measured using a TA XTPlus Texture Analyzer and the Exponenet Software (Stable Micro Systems,Version 6,1,7,0). Volume was measured using a graduated cylinder. Colorwas measured using a Hunter Colorimeter LabScan XE spectrophotometer.

Conclusion

It is to be understood that embodiments of the present disclosuredescribed above are intended to be merely exemplary. Those skilled inthe art will recognize, or be able to ascertain using no more thanroutine experimentation, numerous equivalents to the specific proceduresdescribed herein. All such equivalents are considered to be within thescope of the present disclosure and are covered by the following claims.

It is further contemplated that any embodiment or implementation of thedisclosure manifested above as a system or method may include at least aportion of any other embodiment or implementation described herein.Those having skill in the art will appreciate that there are variousembodiments or implementations by which systems and methods describedherein can be implemented, and that the implementation will vary withthe context in which an embodiment of the disclosure is deployed.

Although the subject matter has been described in language specific tostructural features and/or methodological acts, it is to be understoodthat the subject matter defined in the appended claims is notnecessarily limited to the specific features or acts described above.Rather, the specific features and acts described above are disclosed asexample forms of implementing the claims.

What is claimed is:
 1. A system for producing sprouted popcorn kernelscomprising: a soaking tank sized and dimensioned to receive a charge ofat least 100 lbs. of unsprouted popcorn kernels and a volume of soakingfluid sufficient to cover the charge of unsprouted popcorn kernels, thesoaking tank configured to hold the charge of unsprouted popcorn kernelsin contact with the soaking fluid to provide a moisture content of thecharge of unsprouted popcorn kernels by weight from 29% to 35%; agermination unit coupled with the soaking tank to receive soakedunsprouted popcorn kernels from the soaking tank, the germination unitconfigured to maintain a relative humidity from 30% to 70% to at leastpartially germinate the soaked unsprouted popcorn kernels withoutacrospire formation; a germination sensor coupled with the germinationunit, the germination sensor oriented to detect a germination progressof the at least partially germinated popcorn kernels and generate anoutput signal in response thereto; a controller communicatively coupledwith the germination sensor to receive the output signal, the controllerconfigured to compare the output signal to reference germinationthresholds to determine whether the output signal from the germinationsensor meets or exceeds at least one reference germination threshold;and a drying unit communicatively coupled with the controller, thedrying unit configured to dry the sprouted popcorn kernels to a moisturecontent by weight from 14% to 16% responsive to instructions from thecontroller when the output signal from the germination sensor meets orexceeds at least one reference germination threshold.
 2. The system ofclaim 1, further comprising a moisture sensor coupled with the soakingtank, the moisture sensor positioned to measure a moisture content ofthe charge of unsprouted popcorn kernels.
 3. The system of claim 2,wherein the controller is communicatively coupled with the moisturesensor, and wherein the controller is configured to initiate transfer ofsoaked unsprouted popcorn kernels from the soaking tank to thegermination unit when the moisture sensor detects a moisture content ofthe charge of unsprouted popcorn kernels by weight from 29% to 33%. 4.The system of claim 1, wherein the germination unit is configured toproduce sprouted popcorn kernels having a moisture content by weightfrom 30% to 35%.
 5. The system of claim 1, wherein the germinationsensor includes an optical sensor configured to measure an opacity of ahull of popcorn kernels held within the germination unit, and whereinthe reference germination thresholds include a hull opacity measurementprior to acrospire formation.
 6. The system of claim 1, wherein thegermination sensor includes a moisture sensor configured to measure amoisture content of popcorn kernels held within the germination unit,and wherein the reference germination thresholds include a moisturecontent of sprouted popcorn kernels prior to acrospire formation.
 7. Thesystem of claim 1, wherein the germination sensor includes each of anoptical sensor and a moisture sensor, wherein the reference germinationthresholds include an optical measurement of sprouted popcorn kernelsprior to acrospire formation, and wherein the controller is configuredto activate the moisture sensor to detect a moisture content of popcornkernels held within the germination unit when output from the opticalsensor at least substantially matches the optical measurement ofsprouted popcorn kernels prior to acrospire formation.
 8. The system ofclaim 1, further comprising a moisture sensor coupled with the dryingunit and communicatively coupled with the controller, wherein thecontroller is configured to instruct the drying unit to stop drying thesprouted popcorn kernels when the moisture content by weight measured bythe moisture sensor is from 14% to 16%.
 9. The system of claim 1,further including a decontamination unit configured to receive thecharge of unsprouted popcorn kernels prior to introduction to thesoaking tank, the decontamination unit including an input to receive adecontamination fluid and direct the decontamination fluid to contactthe charge of unsprouted popcorn kernels.
 10. The system of claim 9,wherein the decontamination fluid includes at least one of sodiumhypochlorite (NaOCl) or an organic liquid decontaminating agent.
 11. Thesystem of claim 1, wherein the controller is communicatively coupledwith the soaking tank to provide an activation step and a steeping stepto provide the moisture content of the charge of unsprouted popcornkernels by weight from 29% to 35%, wherein the activation step includessoaking the charge of unsprouted popcorn kernels in the soaking fluid ata temperature of between 30° C. to 60° C. for a first duration, andwherein the steeping step includes soaking the charge of unsproutedpopcorn kernels in the soaking fluid at a temperature of between 20° C.to 30° C. for a second duration greater than the first duration.
 12. Thesystem of claim 11, wherein the first duration is from 15 minutes to 120minutes.
 13. The system of claim 12, wherein the second duration is from4 hours to 8 hours.
 14. The system of claim 11, wherein the activationstep occurs in the absence of light.
 15. The system of claim 14, whereinthe steeping step occurs in the presence of light.
 16. The system ofclaim 1, wherein the germination sensor includes each of an opticalsensor and a moisture sensor, wherein the reference germinationthresholds include an optical measurement of sprouted popcorn kernelsprior to acrospire formation, and wherein when the controller determinesoutput from the optical sensor at least substantially matches theoptical measurement of sprouted popcorn kernels prior to acrospireformation the controller is configured to determine whether a moisturecontent of popcorn kernels held within the germination unit detected bythe moisture sensor is within a moisture threshold, and wherein thecontroller is configured to instruct the drying unit to dry the sproutedpopcorn kernels when it is determined that each of the optical sensoroutput and the moisture sensor output are within the respectivethreshold values.